Planter container liners

ABSTRACT

A liner, blank or sheet ( 1,11,12,21,30,70 ) of compressed sphagnum moss ( 54 ) having a moisture content such that the liner, blank or sheet is pliable to the extent that it is able to be folded and unfolded with minimal or no degradation to the fiber integrity, wherein the liner, blank or sheet of compressed sphagnum moss is provided with means to minimise moisture loss. A method of constructing such a liner blank or sheet is also provided.

[0001] This application is a continuation-in-part of U.S. applicationSer. No. 09/372,291, filed Aug. 11, 1999 which for purposes ofdisclosure is incorporated herein by specific reference.

FIELD OF THE INVENTION

[0002] This invention relates to plant container liners or blankstherefor or sheets of sphagnum moss. In particular, although notexclusively, the invention relates to sphagnum moss liners for plantcontainers such as hanging baskets, especially those baskets in the formof skeletal containers.

BACKGROUND TO THE INVENTION

[0003] Because of its unique water retaining properties, and pleasantappearance as a natural plant substance, sphagnum moss has traditionallybeen a favoured material for use in conjunction with floral arrangementsand related horticultural activities.

[0004] Traditionally, sphagnum moss has been sold mostly in a driedstate but sometimes in a wet state, but generally in a natural looseform in which each filament of the moss plant is separate anddistinguishable.

[0005] In recent decades, a new technology has developed in the sphagnummoss industry. This is the use of pressure to compress the loose moss ina press into compact sheet form. These sheets are of various thickness,usually from 2 or 3 mm to about 7 mm. They are somewhat like cardboardin flexibility and look somewhat like particle board in texture.

[0006] In its traditional loose form, sphagnum moss has always beenassociated with hanging baskets. One reason for this is its particularability to absorb and retain water up to and exceeding 20 times its ownweight. Another is its natural and aesthetically pleasing appearance.

[0007] The most common traditional method of using sphagnum moss to linehanging baskets is to place some loose moss in the bottom of a wirehanging basket, then cover the moss with a little potting mix. Afterthis the basket is gradually filled, firstly by building up the outerlayer of sphagnum moss around the outside of the basket and secondly byholding it in place with a little more soil and potting mix. Thisprocess is repeated several times until the lining of sphagnum mossreaches right to the upper rim of the hanging basket.

[0008] This is obviously a very labour intensive task. For this reasonit has mostly been performed at home by the enthusiastic gardener, andby staff in some garden centres. In this form, hanging baskets with alayer of sphagnum moss directly inside the wire basket can be madeavailable only when they are filled with soil and potting mix, becauseit is the soil and potting mix which holds the outer lining of loosefilaments of moss in place.

[0009] It is evident that there is an extremely limited scope forselling sphagnum moss lined hanging baskets in this form. The labourcontent in filling them is very high. In addition the basket would needto be regularly watered to keep the potting mix and the sphagnum mossmoist.

[0010] For these reasons, sphagnum lined hanging baskets filled in thisway would normally have to be made and sold in the same garden centre.Such articles could not be manufactured on a large scale usingtechnology and production machinery and then transported in bulknationally and internationally to many retail outlets. Consequently onlyvery small numbers of such sphagnum lined baskets are made up in thisway.

[0011] One company in USA has taken a step forward in this regard andcreated a sphagnum moss lined hanging basket which can much more readilybe transported in cartons as freight, or even posted in the mail, whichmakes them much more marketable than the previously mentioned type. Inthese, filaments of loose dry sphagnum moss are fixed onto the outsideof the basket with very fine filament or wire. This means that no soilor potting mix is needed to hold the sphagnum moss in place.

[0012] However, the process of sewing the filaments or moss onto theoutside of the basket is very time consuming and keeps this type of mosslining within the category of a hand crafted item. As such, this type ofliner will always be relatively expensive, limited in numbers, andtherefore a speciality item.

[0013] One New Zealand company also markets a compressed sphagnum mossproduct formed as a blank shaped like a Maltese cross. When placedinside a hanging basket, the edges fold up and contour to the shape ofthe basket. A disadvantage of a liner in this form is that initially atleast, the liner does not conform satisfactorily to the shape of thecurved hanging basket.

[0014] Common features of known compact sphagnum liners are:

[0015] 1 They are both presented to the public in flat, one dimensionalform.

[0016] 2 Both must be placed inside a hanging basket before they canassume and retain the three dimensional shape of the basket.

[0017] 3 Both are in untreated compacted sheet form and bear littleresemblance to sphagnum moss.

[0018] 4 Both have to be assembled by the purchaser according toinstructions supplied.

[0019] Extensive market research conducted on our behalf concerningbasket liners made up of flat sections of compacted sphagnum moss showsthat unless there has been a considerable amount of prior instructionand education, a large proportion of the general public and thegardening public are not aware that:

[0020] such flat shaped pieces of compacted sphagnum moss are in factbasket liners;

[0021] such a smooth surfaced, cardboard-like substance is in factsphagnum moss.

[0022] In addition, the public needs instruction as to how such objectsshould be assembled into their end form as basket liners. In particular,a great deal of care and attention is required to manipulate the blanksto enable them to fit the containers. If the dry compacted sphagnum mossliners are bent to suit the contour of the containers, this leads tocracking. A comparison would be like trying to mould a sheet of balsawood to fit into a bucket. The cracking results in breaking of the mossfibres themselves. This reduces the fibre length of the moss and themoss in and around the cracks may be of insufficient strength toeffectively bind and hold the liner together once filled with soil. Thiscan lead to unattractive holes in the moss with consequent loss of soilthrough the holes. Accordingly, it is necessary to gently wet the sheetsof compressed sphagnum moss before manipulating them into the plantcontainers. Furthermore, the customer ought to take care with the mannerin which the water is applied to the liners. If the temperature of thewater is too high ie in excess of 25° C. or the pressure to great, theuser can easily blow a hole in the liner. Consequently, the degree ofcare required to manipulate the prior art liners may be viewed as veryhigh, perhaps leading to wastage or excessive difficulty by the enduser.

[0023] Consequently, expensive and extensive advertising and promotionalmaterial, and special training of shop sales persons at every point ofsale has been necessary to combat the fact that many people do not know:

[0024] what such objects are and what they are for;

[0025] what they are made of;

[0026] how they are to be assembled.

[0027] In spite of all this instruction, which does increase the priceunnecessarily, many people still pass them by because they do not knowwhat they are, and do not realise how they make up into a basket liner.

[0028] As a result, these liners have been observed in sales outletsbeing progressively moved into obscure positions of display where theygather dust.

[0029] It is an object of the present invention to provide a plantcontainer liner or a blank therefor, which will address at least some ofthe foregoing problems or at least provide the public with a usefulchoice over liners/blanks at present available.

STATEMENTS OF THE INVENTION

[0030] In accordance with a first aspect of the invention, there isprovided a liner for a plant container, the liner including one or moresheets of compressed sphagnum moss and having a moisture content suchthat the liner is pliable to the extent that it is able to be folded andunfolded with minimal or no degradation to the fibre integrity, whereinthe liner is provided with moisture retainer to minimise moisture loss.

[0031] In accordance with a second aspect of the invention, there isprovided a blank configured to form a liner for a plant container, theblank comprised of one or more sheets of compressed sphagnum moss havinga moisture content such that the blank is pliable to the extent that itis able to be folded and unfolded with minimal or no degradation to thefibre integrity, wherein the blank of compressed sphagnum moss isprovided with a moisture retainer to minimise moisture loss.

[0032] In accordance with a third aspect of the invention, there isprovided a sheet of compressed sphagnum moss having a moisture contentsuch that the blank is pliable to the extent that it is able to befolded and unfolded with minimal or no degradation to the fibreintegrity, wherein the blank of compressed sphagnum moss is providedwith a moisture retainer to minimise moisture loss.

[0033] In order to achieve the desired moisture content, the sphagnummoss may be initially dry or substantially dried prior to compaction andthen partially reconstituted following its compaction. The moss may bepre-dried to around 18-20% moisture by weight prior to compaction. Thepartial reconstitution may be achieved by applying a liquid to thecompressed sphagnum moss. Preferably the liquid is substantially water.Most preferably the liquid is applied by a fine mist spray. The amountof applied may be anywhere in the range of 100 g/m² up to 1020 g/m². Forsome forms of the invention, it is preferred that a lesser amount of isapplied, enabling the compressed sphagnum moss when formed into a linerto have walls which retain sufficient stiffness so as to beself-supporting. In this form of the invention, the amount of added ispreferably in the range 113-173 g/m². In a most preferred form of theinvention, the amount of applied is 143 g/m². The is preferably appliedto the side of the blank which forms the exterior of the blank in thefully assembly 3-dimensional form of the liner. This amount of isselected so that the liners, blanks or sheets will be pliable but not sosaturated as to fall apart or lose the self-supporting quality.

[0034] In other forms of the invention, stiffness of the side walls ofthe finished liner is not a requisite feature and accordingly, a greateramount of may be added to the liner, blanks or sheets for a particularlypliable construction. For example, in one form of the invention, theblanks may comprise very large sheets of sphagnum moss intended forlarge plant containers. These blanks may be folded and enclosed in asealed package. The amount of added may be in the range of 960-1020g/m². In a preferred form of this embodiment, 990 g/m² is applied tothese large liners prior to folding and packaging. Additionally, inorder to prevent the layers of sphagnum moss from sticking to each otherwhen folded, a barrier layer may be inserted therebetween. In a mostpreferred form, plastic sheet have a thickness of 15 microns is insertedbetween each of the folded layers.

[0035] The means to minimise moisture loss from the liner, blank orsheet may comprise a substantially sealed package which is waterimpervious. The means to minimise moisture loss may comprise awater-resistant package or wrapping. Suitably the liner, blanks orsheets are enclosed in plastic. Where the liners are assembled intotheir 3-dimensional form then the liners may be individually wrapped ina shrink wrap plastic or nested into one another and shrink wrapped ingroups of three or 4. Where the blanks or sheets of sphagnum moss arefolded, the package may simply comply a plastic bag. The packaging ofthe liners in a water impervious package also prevents additionalmoisture from entering the package and unintentional reconstituting thesphagnum moss.

[0036] However, the invention is not limited to wrapping as a means ofminimising moisture loss. It may be possible to spray the liner blanksor sheets with a coating to achieve this end. For example, a waxycoating could be sprayed onto the liner blanks or sheets which is laterdissolvable to allow full reconstitution of the liners, blanks orsheets.

[0037] In accordance with a fourth aspect of the present invention,there is provided a method of fabricating a blank for a plant containerincluding: partially reconstituting one or more sheets of compressedsphagnum moss which is dried or at least substantially dry, until the oreach sheet reaches a moisture content sufficient to enable the or eachsheet to be pliable to the extent that it is able to be folded andunfolded with minimal or no degradation to the fibre integrity; andproviding the blank of compressed sphagnum moss with a moisture retainerto minimise moisture loss.

[0038] Any of the blanks or liners according to the foregoing aspectsmay incorporate a layer of water resistant material into the liner orblank.

[0039] It would be desirable for the layer of water resistant materialto be sandwiched within the sphagnum moss but towards the outer surfaceof the liner because for visual impact, concealment of the waterresistant layer by a layer of sphagnum moss is desirable. This can beachieved by initially laying a thin layer of the sphagnum moss, then thewater resistant layer and finally the major amount of sphagnum moss tobe compressed.

[0040] It is also intended that a wide range of materials may beutilised to form the water resistant or water impervious layer. In asimple form the layer can be provided by a mat of cellulous materialsuch as a suitable grade of paper which may or may not have surfacecoatings. Suitable surface coatings where provided can facilitateadhesion to the sphagnum moss and increase the water retentivecharacteristics of the layer.

[0041] A suitable plastic sheet may replace the sheet of cellulousmaterial with the surface of the sheet being treated to facilitateadhesion to the sphagnum moss if desired. Aluminium foil is anotherdesirable alternative.

[0042] In a yet further modification, the water resistant layer can beprovided by treating a section of the sphagnum moss with a suitablechemical mixture so that upon heat and pressure, or pressure alone, alayer of the sphagnum moss sheet will assume characteristics resistingwater penetration. For example, a plastics compound which at ambienttemperatures would be in liquid form could be sprayed onto the sphagnummoss and which when subjected to heat and pressure, or pressure aloneforms the required water resistant layer.

[0043] It is also possible within the ambit of the present invention toprovide a liner which has different water retentive characteristics. Forexample, in the base section and a lower part of the wall there could bea water resistant layer but in the upper section of the wall the waterresistant layer may not be included.

[0044] As mentioned above, each blank is generally of a form including acircular base section and a unitary arcuate wall section extendingaround the circular base. In this way, the wall section defines acontinuous wall around the circular base in the assembled form of theliner. In one form of such a blank the base section may be integrallyformed with the wall section along a part of the periphery of the base,allowing the remainder of the wall section to be folded about theremainder of periphery of the base. The blank may be secured in thethree dimensional form by overlapping extension areas of the base and/orthe wall section and by joining together the ends of the wall section byfastening means such as staples passing through the overlapped extensionareas.

[0045] In an alternative form of the invention, the blank may beconfigured to include: a substantially semi-circular base section havinga substantially semi-circular edge; and one or more wall sectionsadapted to fold about the arcuate or semi-circular edge of the basesection to form with the base section, a surrounding wall in the 3dimensional form of the liner wherein at least one of the wall sectionsis integrally formed with the base section along a part of thesemi-circular edge of the base section and is adapted to follow thecontour of the semi-circular edge of the base section in the 3dimensional form of the liner. It will be appreciated that a liner ofthis form will be appropriate for use in a wall mounted hanging basket.

[0046] As discussed, an appropriately shaped mould may be used to formeach of the blanks. Mould loading devices may be utilised to load apredetermined quantity of moss into the recesses of the moulds.

[0047] Alternatively, the sphagnum moss may be compressed into the formof a larger sheet so that a number of blanks may be cut from the sheetand each blank folded to form a three dimensional liner.

[0048] As already mentioned, the blanks or liners described in theforegoing aspects may be comprised of moss which is preferably pre-driedto around 18 to 20 percent moisture by weight prior to compaction intosheets. In a preferred form of the invention, the moss is compressedwithout any additional heat being applied. However, in countries (egAustralia) which exclude the import of any moss other than that which iscertifiably free of viable seed, the moisture content of the sphagnummoss prior to the compaction may be greater to generate steam duringhot-pressing to sterilise the moss. See for example New Zealand PatentSpecification 314613/314825, Australian Patent Specification 6037/98 orChile Patent Specification 1790-98, the contents of which areincorporated herein by reference. However, where possible, thecold-press method is preferred because it is believed that hot-pressingslows the rate at which the compressed sphagnum moss can bereconstituted.

[0049] For transportation it is clearly desirable to ensure that thethree dimensional form of the liners are able to be nested one withinthe other to minimise the transportation space required in sending theliners to the point of sale outlets.

[0050] As mentioned above, packaging is one means of preventingdehydration of the liners. The method may involve: enveloping a singleliner or a plurality of nested liners with shrink wrapping material suchthat the shrink wrapping material extends into the interior of the orthe top liner, weighting the shrink wrapping material with a weightplaced in the interior of the or the top liner; and heat treating theshrink wrapping material to conform to the shape of the liner.

[0051] The invention consists in the foregoing and also envisagesconstruction of which the following give examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] One preferred form of the invention and modifications thereofwill now be described with reference to the accompanying drawings inwhich:

[0053]FIG. 1 illustrates filaments of natural sphagnum moss product asharvested;

[0054]FIG. 2 illustrates the principle of reconstitution of a sheet ofcompressed sphagnum moss;

[0055]FIG. 3 is a bottom perspective view of a mould loading deviceaccording to a preferred embodiment of the present invention;

[0056]FIG. 4 is a top perspective view of the mould loading deviceillustrated in FIG. 3;

[0057]FIG. 5 is a bottom perspective view with the mould loading devicein operation;

[0058]FIG. 6 is a perspective view of a negative mould plate;

[0059]FIG. 7 is a cross-sectional detail of the negative mould plateillustrated in FIG. 6;

[0060]FIG. 8 is a cross-sectional detail of the mould plate illustratedin FIG. 6;

[0061]FIG. 9 is a perspective view of the negative mould plate of FIG. 6illustrating the alignment of a cooperable positive mould member;

[0062]FIG. 10 is a perspective/partial cross-sectional view of thepositive mould member shown in FIG. 9;

[0063]FIG. 11 is a cross-sectional detail of the positive mould memberillustrated in FIG. 10;

[0064]FIG. 12 is a cross-sectional detail of the positive mould memberillustrated in FIG. 10;

[0065]FIG. 13 is a blank of compressed sphagnum moss which may be usedto assemble a plant container liner;

[0066]FIG. 14 is a top view of the three dimensional form of the linerassembled from the blank in FIG. 13;

[0067]FIG. 15 is a side perspective view of the three dimensional linershown in FIG. 14;

[0068]FIG. 16 is a perspective view of the three dimensional liner shownin FIG. 15 with the surface of the exterior of the liner partiallyreconstituted;

[0069]FIG. 17 illustrates the liner of FIG. 16 including a plasticshrink wrapping;

[0070]FIG. 18 is a perspective view of three liners, nested into a stackand bound by plastic shrink wrapping;

[0071]FIG. 19 is a perspective view of the liner of FIG. 16 installed ina conventional hanging basket assembly;

[0072]FIG. 19b is a plan view of a blank for a plant basket;

[0073]FIG. 20 is a blank of compressed sphagnum moss which may be usedto assemble a modified plant container liner;

[0074]FIG. 21 is a top view of the three dimensional liner formed fromthe blank illustrated in FIG. 20;

[0075]FIG. 22 is a front perspective view of the liner in FIG. 21;

[0076]FIG. 23 is a view of a wall blank of compressed sphagnum moss anda separate base blank;

[0077]FIG. 24 shows a top view of the three dimensional liner formedfrom the component parts as illustrated in FIG. 23;

[0078]FIG. 25 is a front view of the liner illustrated in FIG. 24;

[0079]FIG. 26 is a view of a blank for a compressed sphagnum moss lineraccording to another preferred embodiment of the invention;

[0080]FIG. 27 is an inside view of the liner assembled from the blank ofFIG. 26;

[0081]FIG. 28 is a front view of the liner of FIG. 27;

[0082]FIG. 29 is a further detailed view of the blank shown in FIG. 26;

[0083]FIG. 30 is a view of a further preferred form of a blank, similarto that shown in FIG. 26;

[0084]FIG. 31 is a section through a plant container liner manufacturedaccording to an aspect of the present invention; and

[0085]FIG. 32 is a section through an alternative plant container liner.

PREFERRED EMBODIMENTS OF THE INVENTION

[0086]FIG. 1 shows filaments of harvested sphagnum moss 100. Thesphagnum moss 100 is used primarily in the present invention for itswater retentive property which is up to 20 times its own weight inwater. The sphagnum moss 100 is also used for its aesthetic value inhanging basket arrangements. The sphagnum moss is harvested from anatural and renewable source.

[0087] Initially, some of the excess water may be removed from thefreshly harvested sphagnum moss 100 through the use of a centrifuge orcalender rolls. The sphagnum moss 100 is then dried either in a kiln orwith natural sunlight. Preferably, the sphagnum moss 100 is dried in akiln with a continuous conveyor (not shown), the speed of which iscontrollable. Suitably, an automatic feeding system (not shown) thatdeposits the moss onto the kiln's continuous conveyor is also provided.The kiln is in the form of a tunnel and operates to circulate heated airwhich is generated from hot water heat exchangers operating at atemperature as high as 140° C. The moss is gradually dried as it travelsthrough the kiln.

[0088] After drying, the moss may be left in piles to cool and reabsorbsome moisture from the atmosphere. Alternatively, additional moisturemay be added to the moss through the use of pressurised water mistingnozzles. The optimum moisture content of the moss prior to pressing is18 to 20 percent by weight although a range of 14 to 17 percent byweight is commonly used. It is considered that anything in the range of3 to 25 percent by weight will work.

[0089] When an appropriate moisture content has been reached, thesphagnum moss can be compressed into sheets 102 as illustrated in FIG.2. The sphagnum moss sheet 102 has the ability to absorb a significantquantity of water 104 and reconstitute into its substantially originalstate. The sheet 102 illustrated in FIG. 2 is included to provide thereader with an appreciation of the ability of sphagnum moss toreconstitute from a compressed, substantially dried state to itssubstantially original state. Prior to reconstitution, the sheet 102 maybe cut into one or more blanks, each of which may then be assembled toform a three dimensional liner. However, in the most preferred form ofthe invention to be explained by the following text, the sphagnum mossis compressed directly into the form of individual blanks each of which,when assembled forms a three dimensional liner of the form illustratedin FIG. 15. FIG. 9 illustrates the general form of the mould used toform each of the blanks of FIG. 15. The mould includes a negative mouldplate 600 having a number of mould recesses 602 and positive mouldmembers of a shape complimentary to that of the recesses. Accordingly, amould loading device 300 (FIG. 3) is used to load sphagnum moss into themould recesses 602.

[0090] The mould loading device 300 comprises a filling box 302generally conforming to the shape of the mould recess 602 to be filled.The filling box 302 shown in FIG. 3 includes a base 304 and side walls306 but is open at the top as illustrated in FIG. 4. The base 304includes finger slots, the reason for which will be explained.

[0091] The mould loading device 300 further includes a handle portion308 conforming only approximately to the shape of the filling box 302.Dependent from the handle portion 308 are four dowels 310 (only three ofwhich are shown). These dowels 310 are fixed to the handle portion 308at spaced locations but extend slidingly through apertures provided inthe base 304 of the filling box 302. As can be seen in FIG. 5, thedowels 310 are attached to a false bottom 316 which is complimentary inshape to the base of the filling box. The false bottom 316 is slidablewithin the filling box 302 and is controlled by the handle portion. InFIG. 3, the handle portion has been pulled out as far as possible sothat the false bottom 316 engages against the inside of base 304. Inthis configuration, the spring loaded latch 318 has a pin which extendsinto an aperture provided in centre dowel 310. This holds the falsebottom 316 in position against the inside of base 304 during filling andtipping.

[0092] In use, the moss loading device is oriented in FIG. 4 with thehandle portion 308 fully extended and the latch in position in the dowel310. Sphagnum moss 100 is inserted into the open end of the filling box302. Once filled, the mould loading device is weighed on electronicscales to ensure that an appropriate quantity of moss has been insertedinto the filling box. An appropriate amount might be approximately 869g/m² of area of the finished blank. Once filled to a satisfactory level,the mould loading device 300 is brought to the negative mould plate 600(FIG. 6, FIG. 9) and the loading device is deftly flipped over so thatthe opening is in register with the mould recesses 602 of the mouldplate 600. To ensure adequate removal of the contents of the mouldloading device 300, the latch 318 is released to allow the user to pushhandle portion 308 towards the base 304. The handle portion 308 isconfigured to enable the user to use both hands to extend aroundrespective parts of the handle portion 308 with the users fingersinserted through the finger slots 305. Squeezing together of the portionof the base between the finger slots 305 and the handle portion 308ensures full ejection of the sphagnum moss 100 from the filling box 302into the mould cavity 602. Depending on the size of the filling box 302and the predetermined correct weight of the moss in the filling box, thethickness of the moss deposited into each mould recess will beapproximately 60 to 85 mm.

[0093] The negative mould plate 600 illustrated in FIG. 6 has a regulararray of mould recesses 602 shaped so that the blanks produced therebywill conform to those illustrated in FIG. 13, to enable the assembly ofthe three dimensional liner illustrated in FIG. 15, with little if anywastage of sphagnum moss material.

[0094] The negative mould plate 600 is primarily constructed of a highdensity PVC foam material 700 sold under the trade mark KLEGECELL. Thehigh density foam material 700 is sandwiched between two sheets ofplywood 702, 704. The sheet 702 forms the upper surface of the mould andthe sheet 704 defines the lower periphery of the high density foammaterial 700. A further sheet of plywood 706 is disposed to define thebase of the negative mould plate 600.

[0095] The high density PVC foam material 700 is of the type commonlyused in the construction of surfboards, sailboards and in general boatand yacht construction. Suitably the high density foam material shouldbe both light and strong. The choice of plywood for the sheet 702, 704,706 has been made because plywood is able to withstand the highpressures applied to it during the pressing process (500 - 3500 psi)(3.448 - 24.133 MPa).

[0096] All of the layers in the negative mould sheet 600, apart from thebase layer 706 are cut to remove portions in the shape of the blanks tobe formed by the mould recesses 602. Each of the layers 700, 702, 704 isprovided with the cut outs in register with each other so that when thelayers are stacked one on top of each other, the layers will define themould recesses 602. Only the base layer of plywood 706 remains in tactand thereby defines the base of the mould recesses 602. The depth of themould recesses can range between 35 and 90 mm depending on theapplication. The layers are glued together to form a laminate. Thesurface of the foam layer 700 defining the working surface of the mouldrecess 706 is provided with a fibreglass coating 800 to protect theworking surface of the foam layer 700 from abrasion during pressing. Thefibreglass coating 800 may include polyester, vinyl ester or epoxyresins and chop strand matt as is known to those skilled in the art offibreglass.

[0097] The positive mould members 900 illustrated in FIGS. 9 to 12 arecomprised of four sheets of plywood including a top sheet 910 of 7 mmplywood, a base sheet 920 of 12 mm plywood and two inner sheets 930, 940of 12 mm plywood. The inner sheets of plywood 930, 940 are machined witha plurality of fairly evenly spaced apertures 950 which serves to reducethe weight of the positive mould member 900. The layers of plywood 910,920, 930, 940 are glued together to form a laminate.

[0098] The shape of each positive mould member 900 (excluding positivemould member 901 illustrated in FIG. 16a) is complimentary to the shapeof each mould recess 602, except that the positive mould member 900 issmaller than the mould recess 602 so that a gap of between 2 and 3 mm isprovided between the sides of the positive mould member 900 and the sidewall of the mould recess 602 when the positive mould member 900 isinserted into the mould recess 602. Additionally, the positive mouldmembers 900 are formed so as to be 5 to 10 mm thicker than the depth ofthe mould recesses 602. In this way, when the full pressure of the pressbears on the positive moulds, no pressure will be exerted onto the topsurface of the negative moulds. In view of the foam material, pressureon the negative mould plate 600 might cause it to be crushed.

[0099] In use, the mould recesses 602 of the negative mould plate 600are filled in turn with sphagnum moss using the mould loading device300. When all of the mould recesses 602 have been loaded with sphagnummoss, each of the positive moulds 900 is inserted into a respectivemould recess 602. The assembly of the negative mould plates 600 and thepositive mould members 900 is thus ready for insertion between theplatens of a platen press (not shown). The press may be of aconventional type with the assembly of the mould plate 600 and mouldmembers 900 being carried or conveyed to the press and inserted betweenthe platens thereof, prior to the platens being brought together tocompress the sphagnum moss within each of the mould recesses 602. Thepressure for pressing the moss range is between 500 psi and 3800 psi(3.448 - 26.201 MPa) for a time ranging between 10 seconds and 3minutes. The combination of pressure and time is such that the thicknessof the blanks produced is between 2.5 and 4 mm and yet still able toreconstitute with the addition of water. This degree of compressionprovides the blank with sufficient rigidly to enable the walls of theassembled three dimensional liner to be self supporting. It isconsidered that a compressed thickness of between 1 mm and 6 mm for thestated pre-compression thickness of moss should also provide sufficientrigidly for the walls to be self-supporting.

[0100] In an alternative type press (not shown) the lower platen may beprovided in the form of a table slidable into and out of the press. Inthis embodiment, the positive mould members are affixed to the upperplaten of the press and the negative mould plate is affixed to the lowerplaten of the press. When the lower platen is moved into position insidethe press, the mould recesses and the positive mould members are inprecise alignment. With this arrangement, the negative mould plate 600may be conveniently accessed for loading and unloading by sliding thetable out of the press. In another alternative form of the press, theupper platen may be tiltable to provide increased access to the negativemould plate 600.

[0101] As illustrated in FIG. 13, the blank 1 which will be formed usingthe mould assembly of negative mould plate 600 and positive mould plate900 has an arcuate wall section 2 and a circular base integrally formedwith the wall section. An extension 4 at one end of the wall section 2provides for an overlap to occur between the joining wall sections whenfolded about the base 3. Connecting staples 9 pass through theoverlapped sections to retain the wall section of the liner assembled inthe three dimensional form as illustrated in FIG. 14.

[0102] The extension 5 beyond the perimeter of the base 3 indicated indotted outline in FIG. 13 and the tab 7 can be folded up during assemblyto overlap the lower periphery of the wall 2 and an attaching staple 10passing through the tab 7 and wall of the blank will complete theassembly of the three dimensional liner 11 illustrated in FIGS. 14 and15. Other forms of fastening are also considered within the scope of thepresent invention. The compressed sphagnum moss liner 11 has theappearance of cardboard and consequently is not easily recognisable tothe purchasing public as a sphagnum moss liner. To bring the surface ofthe sphagnum moss liners to resemble their original natural state, afine mist of water is sprayed onto the exterior side of the blank only,prior to assembly using an atomised fluid spray to produce a fine mist.The amount of water is about 113-173 g/m², preferably 143 g/m². Thetemperature of the water is also controlled within a range of 15-25° C.This serves to at least partially reconstitute the surface layer of theblank 1 on one side. The blank 1 is then assembled into the threedimensional form of the liner 11 optionally through the use of theconnecting staples 9 in the manner illustrated in FIGS. 14 and 15. Theassembled liner will resemble that illustrated in FIG. 16 with thesurface layer 11 a of the exterior of the blank 11 reconstituted asillustrated. The degree of reconstitution (143 g/m² of water) enablesthe liner to be pliable to the extent that it is able to be folded andunfolded with minimal or no degradation of the fibre integrity and yetenables the walls of the liners to be sufficiently stiff as to beself-supporting. To prevent drying out, the liners are enclosed in asealed package as discussed in connection with FIG. 17. If the linerswere to dry out they would become brittle and thus susceptible to damageand fragmentation which would render them inoperable.

[0103] Following stapling, the liners 11 have appropriate productinformation and advertising sheets placed in or over the liners 11 insuch a manner that they contour to the curved surfaces of the liners 11.

[0104]FIG. 17 illustrates the liner 11 enclosed within a bag 11 b ofwater-impervious shrink wrap plastic of 19 micros in thickness. The bagis sealed in a circular shape around the top of the liner 11, 10 to 100mm from the top edge with a purpose built circular sealing machine. Thisprovides a surplus of plastic which fits down inside the liner 11against the sides and the bottom. The plastic is held in positionagainst the sides and bottom of the liner 11 by a purpose built framefitting the outside and the inside of the liner which clamped togetherholds the plastic in place. The wire frame conforms to the inner contourof the liner 11. As the wire frame (not shown) is inserted into theliner 11, the plastic is held against the sides and bottom of the liner.Holes punched into the plastic prior to sealing enable air trappedinside the bag to escape when the wire frame is inserted into the liner.The liner 11 with the sealed bag and the purpose built frame is passedthrough a shrink oven akin to a conveyor bread oven. The liner 11 andaccompanying wrap is then allowed to cool, after which the purpose builtframe is removed. The result is that the plastic still lies snug againstthe interior and the bottom of the liner and not stretched tightlyacross the top of the liner 11 as would occur in conventional shrinkwrapping.

[0105] The use of a circular bag with a circular sealer eliminatesbunching of the plastic on the outside of the liner which would occurwith the use of a square bag. Additionally, with three liners nestedtogether and shrink wrapped as a pack of three, the shrink wrappingprocess has the additional benefit of compacting the liners more tightlytogether than prior to wrapping. This enables more three-packs to fitinto a cardboard carton than a single shrink wrapped package.

[0106] The intended use of the liner is illustrated in FIG. 19. Asshown, the liner 11 is inserted into a conventional hanging basketassembly 11 d. Once the liner 11 is inserted into the basket, it may befully reconstituted by having water poured over or by being soaked inwater for a matter of minutes, to enable full reconstitution to occur.

[0107] It will be appreciated that depending upon the shape of theblank, various liner shapes can be created. Generally, it is desirablethat the shape is one which can allow nesting of similar shaped liners.Such nesting configurations are employed where the assembly step isperformed at a site remote from the point of sale.

[0108]FIG. 19b illustrates the form of a compressed sphagnum moss blankfor a plant container of a specific form. The blank is particularlylarge and so it must be folded up to be transported from the place ofmanufacture to the point of sale. The blank is formed accordingly to theprocesses set out above. Once formed, one side of the blank is partiallyreconstituted with water in the amount of 990 g/m². This is merely apreferred amount and an acceptable range lies between 960-1020 g/m².Once the compressed sphagnum moss blank has been sprayed with waterhaving a temperature in the range of 15-25° C. by an atomised fluidspray, the blank may be folded up. Suitably, plastic sheeting of 15microns in thickness is inserted between the layers of the folded blankto prevent the layers from sticking to each other. The folded blanks arethen inserted into plastic bags of 60 microns in thickness. A partialreconstitution of the large sphagnum moss liners provides them withsufficient pliability to fold into a plastic bag and then to be unfoldedto fit into a plant basket after sale without any further spraying.

[0109] An illustration of another possible modified blank and linerformed therefrom is illustrated in FIGS. 20 to 22 of the accompanyingdrawings. In FIG. 20 the blank 12 of compressed sphagnum moss isprovided with a side wall section 13 and an integral base section 14.The shape is designed to create a three dimensional liner which, whenassembled is, suitable for a plant container supported against a surfacesuch as a wall. The overlap section 15 allows the joining ends of thewall section to be connected and the extension section 16 with tab 17 isupturned to join by way of staples 18, 19, the base in a manner similarto that previously described in connection with FIGS. 13 to 15.Optionally, the exterior of the liner 20 is then sprayed with water.

[0110] A further modification of the present invention allowing a linerto be assembled from a base and wall section is illustrated in FIGS. 23to 25 of the drawings. A wall blank 21 of compressed sphagnum moss isprovided together with a separate base member 22 having a lip 23. Anoverlap section 24 allows for the joining ends of the wall using staples25. The lip 23 is upturned and then connected to the lower end of thewall with staples 26 thereby completing the three dimensional liner 27as illustrated in FIGS. 24 and 25. The wall section 21 is shown with ascalloped upper periphery that is also produced as a scalloped finish inthe assembled liner 27. Optionally, the exterior of the liner is thensprayed with water to partially reconstitute the outer surface layer.

[0111] It will be appreciated from the above description of the methodof manufacture that from an outward appearance it is not easy todistinguish between a liner that has been formed to incorporate a waterretentive barrier within the compressed sphagnum moss and one which doesnot have such a barrier. Establishing a distinctive peripheral edge suchas the scalloped edge 28 could be used to provide a visual distinctionindicating to a user that the liner has a water retentive barrier.

[0112] According to another embodiment of the invention, the blank 30illustrated in FIG. 26 is assembled to form a liner 32 for insertinginto a wall mounted hanging basket or container (not shown) of the kindwhich has a planar semi-circular back section for mounting against asupporting wall surface and a curved front wall section, generallyconforming to the surface of a quarter sphere. Such baskets orcontainers have an open top for insertion of the plant.

[0113] The blank 30 is of integral construction, having a back section34, a first front section 36 and a second front section 38. The backsection 34 is substantially semi-circular in shape and is connected tothe second front section at a central portion of its curved periphery.On the remainder of its curved periphery on either side of the centralconnected portion, the back section 34 is provided with overlap sections40,42. These overlap sections are folded at approximately right anglesto the back section 34 to overlap with the rear edges 43,44 of thesecond front section 38. Optionally, these overlap sections 40,42 couldbe clipped to assist with joining to the rear edges 43,44 of the secondfront section 38.

[0114] The first and second front sections 36, 38 are shaped so thatwhen assembled together they will approximately conform to the shape ofthe surface of a quarter sphere. The two divisions between the first andsecond front sections 36,38 are thus in the manner of darts commonlyemployed in the construction of garments. At each of the two divisionsbetween the first and second front section 36,38 are overlap sections46,48. These overlap sections 46, 48 overlap respective adjacent edgesof the first front section 36 in the assembled configuration of theliner 32. The overlap sections 46,48 could be clipped to assist theassembly process.

[0115]FIG. 29 illustrates a further detailed view of the blank of FIG.26 . If the rear edges 43,44 of the second front section 38 were to becurved around to follow the corresponding periphery of the back section34, as indicated by the phantom lines, then point 50 on the second frontsection 38 would correspond to point 52 on the back section 34. Instead,the shape of the blank is such that the second front section 38 isextended as shown in FIG. 29 so that point 54 meets with point 52 on theback section. The rear edges 43,44 of the second front section 38 musttherefore be gathered or drawn inwards and/or the overlap sections 40,42stretched to achieve the specified fit. This is required to achieved thedesired spherical fullness to the assembled liner. The overlap sections40,42 are stapled near to the rear edges of the second front section 38.

[0116] Similarly, point 58 on the first front section 36 would normallymeet with point 57 on the second front section 38. Instead, point 58meets with point 59. The forward edges of the second front section 38must therefore be gathered and/or the adjacent edges of the first frontsection 36 stretched to achieve the required fit and accordingly obtainthe desired fullness for the assembled liner 32. The joins are securedby staples.

[0117] On assembly, the overlap portions 46,48 of the first frontsection 36 are joined to the second front section followed by thejoining of the back section 34 to the second front section 38. Staplesare used to secure the joins and hold the liner in the assembledconfiguration.

[0118] It will be appreciated that the blank illustrated in FIGS. 26 and29 need not be of integral construction and could be constructed of twoor more parts. For example, the back section 34 could be formed as adiscrete component of the liner with appropriate joining tabs providedon either the back section or the second front section. Additionally,the first and second front sections 36,36 could also be discrete.

[0119] Once the liner, in whatever form, has been assembled into a threedimensional form, the treatment of the outer surface of such a completeliner with moisture to a sufficient degree allowing the reconstitutionof the outer section of the sphagnum moss gives an enhanced visualappearance making it easily possible for a prospective customer torecognise the liner as having been formed from sphagnum moss. It isdesirable to ensure treatment allows only the required partialreconstitution of the liner and of course this step can be more easilycontrolled using the form of the invention where there is a waterresistant layer.

[0120] The incorporation of a water resistant layer into a plantcontainer liner is illustrated in FIGS. 31 and 32. The liner is formedfrom a sheet 61 which may be primary comprised of dried plant materialin layers 4 and 5 such as coconut fibre or sphagnum moss. Where moss isused, preferably the moss has the moisture content reduced so that itcan be compressed into a sheet form. The moisture level has not beenreduced to a degree that the moss itself has an unacceptable brittlenessor inability to reconstitute.

[0121] The sheet 61 has incorporated towards one surface a layer ofwater resistant or water impervious material 62. In one form thisbarrier can be provided by a layer of paper 63 or suitable plasticsmaterial with one or both surfaces, if required, treated to facilitateadhesion to the sphagnum moss when compressed.

[0122] Desirably a thin layer of sphagnum moss 64 is placed in a mould,the barrier placed in position and the remaining mat 65 of sphagnum mossplaced over the barrier 62 prior to compression. Thus, once compressed,the sheet of sphagnum moss has an outward appearance of a normalcompressed sheet of sphagnum moss but has a water resistant barrier 62towards one surface thereof.

[0123] In FIG. 32 the barrier is provided by treating a layer of themoss with a suitable substance. The first layer 4 of moss fibrous plantmaterial placed in the mould may be treated by spraying a thermo settingplastic material. Any curable plastic mixture could be applied dependingupon whether the sheet was to be hot or cold pressed.

[0124] Where the sheet is a liner for a plant container, the sheet canbe formed using the moulds described in connection with FIGS. 3 to 12.Alternatively, the sheet may be formed using a roll press with theprepared bed of sphagnum moss passing through one or a series of rollersto form the desired compaction of the sphagnum moss. Where it isdesirable for the end use of the material to be laid over a largesurface, the more continuous form of compressing would be an advantagewith the completed product delivered in rolls which could be easilyhandled when covering larger surface areas.

[0125] One such application of the invention would be to provide anundersurface for a lawn in arid or semi-arid conditions with the waterresistant or substantially impervious layer provided in the sheet. Thesheet according to the present invention will retain moisture allowingan even watering of an area, for example, of lawn with the applicationof a subterranean watering system using the drip feed technique. Theresult achieved in the present invention provides an evenness ofmoisture over the area of lawn and this can be contrasted with an areaof lawn on an untreated bed of sphagnum moss where the moisture patternthroughout the watered area is uneven. This is because the barrier inthe sheet according to the present invention operates to restrictmovement of water allowing the moss to become saturated. It isrecognised that sphagnum moss presents a desirable environment for rootgrowth.

[0126] Hot and cold pressing creates different reconstitutioncharacteristics in a compressed sphagnum moss sheet. Hot pressingestablishes a longer reconstitution time whereas with cold pressingreconstitution occurs much more rapidly. When the liner 11 asillustrated in FIG. 16 is folded into the basket and the mossreconstitutes, the expansion caused by reconstitution and the forcesgenerated through that expansion tend to compress the joints therebyrestricting the amount of moisture which will be lost through thesejoints. While the openings allow for appropriate drainage to avoidstagnation problems they do restrict the amount of moisture which isable to penetrate to the outer surface of the compressed sphagnum mosssheet. This means that the visual appearance of the liner is retainedand does not visually deteriorate as with conventional sphagnum mossliners. In conventional liners, moisture in the outer surface of themoss causes a green algae growth giving a visually less pleasantappearance.

[0127] One of the greatest causes for moisture loss from the hangingbasket is the evaporation surface created by the outer surface of aconventional liner. This evaporation is accentuated in any conditionswhere there is a draft or movement of air but with the present inventionbecause of the water resistant barrier, such evaporation is minimisedthereby retaining moisture within the hanging basket.

[0128] With the significant reduction of water loss it is not necessaryfor the hanging baskets to be watered as regularly to retain optimumgrowing conditions. With conventional basket liners and untreatedsphagnum moss liners it is frequently necessary to water the plants atleast daily and sometimes more than once a day depending upon ambientconditions to preserve a healthy environment for the plant. With thepresent invention the watering programme can be modified and whileconditions will determine the required maintenance, much greater gapsbetween watering are possible.

What we claimed is:
 1. A liner for a plant container, the linerincluding one or more sheets of compressed sphagnum moss and having amoisture content such that the liner is pliable to the extent that it isable to be folded and unfolded with minimal or no degradation to thefibre integrity, wherein the liner is provided with a moisture retainerto minimise moisture loss.
 2. The liner as claimed in claim 1 formedfrom sphagnum moss which is compressed and dry or substantially driedand then partially reconstituted to the desired moisture content.
 3. Theliner as claimed in claim 2 wherein the partial reconstitution isachieved by applying a liquid to the compressed sphagnum moss.
 4. Theliner as claimed in claim 3 wherein the liquid comprises substantiallywater.
 5. The liner as claimed in claim 4 wherein the liquid is appliedby a fine mist spray.
 6. The liner as claimed in claim 4 wherein theliquid is applied to the exterior of the liner.
 7. The liner as claimedin claim 6 wherein the amount of liquid applied is in the range of 100to 1020 g/m² of the surface area of the exterior of the liner.
 8. Theliner as claimed in claim 7 wherein the amount of liquid added is in therange 113-173 g/m² of the surface area of the exterior of the liner. 9.The liner as claimed in claim 8 wherein the amount of liquid applied isabout 143 g/m² of the surface area of the exterior of the liner.
 10. Theliner as claimed in claim 1 wherein the moisture retainer is in the formof packaging.
 11. The liner as claimed in claim 7 wherein the moistureretainer comprises a water-resistant package or wrapping.
 12. The lineras claimed in claim 10 wherein the packaging is plastic.
 13. The lineras claimed in claim 11 wherein the package or wrapping is plastic.
 14. Ablank configured to form a liner for a plant container, the blankcomprised of one or more sheets of compressed sphagnum moss having amoisture content such that the blank is pliable to the extent that it isable to be folded and unfolded with minimal or no degradation to thefibre integrity, wherein the blank of compressed sphagnum moss isprovided with a moisture retainer to minimise moisture loss.
 15. Theblank as claimed in claim 14 formed from sphagnum moss which iscompressed and dry or substantially dried and then partiallyreconstituted to the desired moisture content
 16. The blank as claimedin claim 15 wherein the partial reconstitution is achieved by applying aliquid to the compressed sphagnum moss.
 17. The blank as claimed inclaim 16 wherein the liquid comprises substantially water.
 18. The blankas claimed in claim 17 wherein the liquid is applied by a fine mistspray.
 19. The blank as claimed in claim 17 wherein the liquid isapplied to a first side of the blank.
 20. The blank as claimed in claim19 wherein the amount of liquid applied is in the range of 100 to 1020g/m² of the surface area of said first side of the blank.
 21. The blankas claimed in claim 20 wherein the amount of liquid added is in therange 113-173 g/m² of the surface area of said first side of the blank.22. The blank as claimed in claim 21 wherein the amount of liquidapplied is about 143 g/m² of the surface area of said first side of theblank.
 23. The blank as claimed in claim 1 wherein the moisture retaineris in the form of packaging.
 24. The blank as claimed in claim 17wherein the moisture retainer comprises a water-resistant package orwrapping.
 25. The blank as claimed in claim 23 wherein the packaging isplastic.
 26. The blank as claimed in claim 24 wherein the package orwrapping is plastic.
 27. The blank as claimed in claim 17 wherein theamount of liquid applied is in the range of 960-1020 g/m² of the flatarea of the blank.
 28. The blank as claimed in claim 27 wherein theamount of liquid applied is about 990 g/m² of the flat area of theblank.
 29. The blank as claimed in claim 27 , in folded configurationand enclosed in a package.
 30. The blank as claimed in claim 29including a barrier layer inserted between the folds of the blank.
 31. Asheet of compressed sphagnum moss having a moisture content such thatthe blank is pliable to the extent that it is able to be folded andunfolded with minimal or no degradation to the fibre integrity, whereinthe blank of compressed sphagnum moss is provided with a moistureretainer to minimise moisture loss.
 32. The sheet as claimed in claim 31formed from sphagnum moss which is compressed and dry or substantiallydried and then partially reconstituted to the desired moisture content.33. The sheet as claimed in claim 32 wherein the partial reconstitutionis achieved by applying a liquid to the compressed sphagnum moss. 34.The sheet as claimed in claim 33 wherein the liquid comprisessubstantially water.
 35. The sheet as claimed in claim 34 wherein theliquid is applied by a fine mist spray.
 36. The sheet as claimed inclaim 34 wherein the liquid is applied to a first side of the sheet. 37.The sheet as claimed in claim 36 wherein the amount of liquid applied isin the range of 100 to 1020 g/m² of the surface area of said first sideof the sheet.
 38. The sheet as claimed in claim 37 wherein the amount ofliquid added is in the range 113-173 g/m² of the surface area of saidfirst side of the sheet.
 39. The sheet as claimed in claim 38 whereinthe amount of liquid applied is about 143 g/m² of the surface area ofsaid first side of the sheet.
 40. The sheet as claimed in claim 31wherein the moisture retainer is in the form of packaging.
 41. The sheetas claimed in claim 34 wherein the moisture retainer comprises awater-resistant package or wrapping.
 42. The sheet as claimed in claim40 wherein the packaging is plastic.
 43. The sheet as claimed in claim41 wherein the package or wrapping is plastic.
 44. The sheet as claimedin claim 34 wherein the amount of liquid applied is in the range of960-1020 g/m² of the flat area of the sheet.
 45. The sheet as claimed inclaim 44 wherein the amount of liquid applied is about 990 g/m² of theflat area of the sheet.
 46. The sheet as claimed in claim 44 , in foldedconfiguration and enclosed in a package.
 47. The sheet as claimed inclaim 46 including a barrier layer inserted between the folds of thesheet.
 48. A method of fabricating a blank for a plant containerincluding: partially reconstituting one or more sheets of compressedsphagnum moss which is dried or at least substantially dry, until the oreach sheet reaches a moisture content sufficient to enable the or eachsheet to be pliable to the extent that it is able to be folded andunfolded with minimal or no degradation to the fibre integrity; andproviding the blank of compressed sphagnum moss with a moisture retainerto minimise moisture loss.
 49. The method as claimed in claim 48 whereinthe partial reconstitution is achieved by applying liquid to thecompressed sphagnum moss.
 50. The method as claimed in claim 49 whereinthe liquid comprises substantially water.
 51. The method as claimed inclaim 50 wherein the liquid is applied by a fine mist spray.
 52. Themethod as claimed in claim 50 wherein the liquid is applied to a firstside of the blank.
 53. The method as claimed in claim 52 wherein theamount of liquid applied is in the range of 100 g/m² to 1020 g/m² of thesurface area of the first side of the blank
 54. The method as claimed inclaim 53 wherein the amount of liquid added is in the range 113-173 g/m²of the surface area of the first side of the blank.
 55. The method asclaimed in claim 54 wherein the amount of liquid applied is about 143g/m² of the surface area of the first side of the blank.
 56. The methodas claimed in claim 48 wherein the moisture retainer is in the form ofpackaging.
 57. The method as claimed in claim 50 wherein the moistureretainer comprises a water-resistant package or wrapping.
 58. The methodas claimed in claim 57 wherein the packaging is plastic.
 59. The methodas claimed in claim 56 wherein the water-resistant package or wrappingis plastic.
 60. The method as claimed in claim 50 wherein the amount ofliquid applied is in the range of 960-1020 g/m² of the flat area of theblank.
 61. The method as claimed in claim 60 wherein the amount ofliquid applied is about 990 g/m² of the flat area of the blank.
 62. Themethod as claimed in claim 60 , wherein the blank is folded and enclosedin a package.
 63. The method as claimed in claim 62 including a barrierlayer inserted between the folds of the blank.